Elevator Application Guide Installation & Operating Manual 3/97 MN770
Table of Contents Section 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Drive Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 General Information Section 5 Set-Up Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 DC SCR Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Field Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 General Information Introduction Drive Definition Baldor Electric manufactures several different Drive types for the elevator industry. These drives are DC SCR (Thyristor), AC Inverter (VVVF) and AC Vector. Each drive type is best suited for a specific application in the elevator market. This manual provides information for selection and application of Baldor Drives for use in the elevator industry. Baldor’s definition of a “Drive” includes both the Motor and the Control.
Section 1 General Information Limited Warranty For a period of two (2) years from the date of original purchase, BALDOR will repair or replace without charge controls which our examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions and/or ratings supplied.
Safety Notice This equipment contains voltages that may be as great as 1000 volts! Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.
Section 1 General Information 1-4 General Information Caution: To prevent equipment damage, be certain that the electrical service is not capable of delivering more than the maximum line short circuit current amperes listed in the appropriate control manual, 230 VAC or 460 VAC maximum per control rating. Caution: Disconnect motor leads (T1, T2 and T3) from control before you perform a “Megger” test. Failure to disconnect motor from the control will result in extensive damage to the control.
Section 2 Technologies Overview Baldor Electric manufactures six drive types for the elevator industry. Each drive type (Control and Motor) is best suited for a specific application. These Series “H” Controls are: S S S S S S S 15H Inverter 17H Vector (Encoderless) 18H Vector 19H DC SCR 20H DC SCR (Line Regenerative) 21H Inverter (Line Regenerative) 22H Vector (Line Regenerative) These Baldor Series “H” controls all use the same keypad and display interface.
DC SCR Control NEMA Type C designation of electrical power source equipment for adjustable speed drives. Series 19H DC SCR (not used in elevator applications) Series 20H DC SCR (Line Regenerative) DC SCR controls are used in elevator applications where speeds range from 50 to over 1000 FPM. The Baldor DC SCR (Thyristor) control is a three phase, full wave rectified, DC motor armature and field (where applicable) control. The SCR bridge converts three phase AC to DC power.
Inverter Series 15H Series 21H Inverter Inverter (Line Regenerative) IEEE-519 Compliant Typically Inverters are used in elevator applications where speeds up to 150 FPM are required. The Baldor inverter converts the three phase AC line power to fixed DC power. The DC power is then pulse width modulated into synthesized three phase AC line voltage for the motor. The rated horsepower of the control is based on a NEMA design B four pole motor and 60Hz operation at nominal rated input voltage.
Vector Series 17H Series 18H Series 22H Encoderless Vector Vector Vector (Line Regenerative) Vector drives are used in elevator applications where speeds range from 50 to over 700 FPM. Baldor is a pioneer in Flux Vector Technology and we continue to be the leader in new product development with our Series 18H Vector Drive, Series 22H Line REGEN Vector Drive and our recently introduced 17H Encoderless Vector Drive. These are three phase, variable voltage and variable frequency controls.
Section 3 Application Considerations General Considerations A good understanding of elevator applications and requirements is essential for proper selection of drive components. Several classifications or categories can be identified to make selection easier. These are: 1. The speed of the car in the hoistway. Generally speaking, there are low speed, medium speed and high speed elevators. 2. The type of hoisting drive used in the elevator. These include hydraulic, mechanical and electric.
Section 1 General Information Electric Drives Electric drives overlap both of these technologies at their upper limits of speed and extend to elevator speeds of more than 700 feet per minute. Cable traction elevators are suspended by cable which is wrapped around a drum. The elevator has a counter weight to eliminate having to dead lift the load as in a hoisting application. These cable drums traditionally have been driven by DC motors powered from a motor - generator set.
Section 1 General Information Common Control Features S Wide Input Voltage Range 180 - 264 VAC 60 Hz 340 - 528 VAC 60 Hz 180 - 230 VAC 50 Hz 340 - 460 VAC 50 Hz S Keypad operation - A common keypad is used for all Baldor Series H Controls. The keypad is used to program and operate the control. S Plain English display - The keypad has a 32 character alpha-numeric display. This display shows the control status and parameter settings in plain English.
Section 1 General Information Elevator Motor Horsepower Selection Selection of a motor and control for an elevator application is dependent upon several variables. The primary variable is the overall mechanical efficiency of the elevator. The efficiency of gear driven elevators varies from about 45 percent for slow moving cars to 70 percent for faster moving cars. On gear-less elevators, efficiency may be in the 90 percent range.
Section 1 General Information Table 3-2 can be used to determine the size control and motor to use for your application. Find the “Car Speed” column in the first row of the table. Follow that column down to find the “Car Capacity” row. Follow that row to the left and read the recommended HP/KW size of the motor. Table 3-2 Motor Sizing Car Speed Feet / Min. 100 150 200 250 300 350 400 500 700 Car Speed Meters / Sec. 0.5 0.75 1.0 1.25 1.5 1.75 2.0 2.5 3.
Section 1 General Information Dynamic Brake Hardware Selection 15H and 18H Drives Baldor Series 15H Inverters and Series 17H and 18H Vector Drives require optional dynamic brake hardware to dissipate regenerative power from the motor. The conditions causing regeneration for an elevator occur about 50 percent of the time the car is moving. This regenerative power is produced when: 1. When a lightly loaded car is being raised. 2. When a fully loaded car is being lowered. 3.
Section 4 Hardware Information General Considerations All Baldor Series H drives are designed for ease of use. The keypad interface provides the same interface for each Series H control. In other words, if you are familiar with parameter set-up for one Series H drive type, the set-up for another Series H drive is similar. Power and logic wiring are essentially the same. Depending on the technology, feedback wiring may be different.
Figure 3-1 Encoder Cables Mylar Sleeve Figure 3-2 Encoder Connections See Control manual for proper terminal tightening torque.
Section 1 General Information Encoder Cable Connection Encoder cable must be separated by at least 3” from parallel runs of power wires. Encoder cables that cross power wires must cross at a 90° angle only. Encoder wires must be #22 AWG (0.34mm2) minimum, 200 feet maximum length and must have an overall shield. Note: Be careful not to pinch the wires’ insulation in terminal. If insulation is caught in screw terminal, proper electrical connection will not be made. Encoder will not operate properly. 1.
Buffered Encoder Output The DC SCR and Vector controls provides a buffered encoder output on pins J1-31 to J1-38 as shown in Figure 3-3. This output may be used by external hardware to monitor the encoder signals. It is recommended that this output only drive one output circuit load. Driving multiple loads is not recommended. Figure 3-3 Buffered Encoder Output See Control manual for proper terminal tightening torque.
Section 5 Set-Up Information DC SCR Controls DC motors use voltage to obtain their speed and current to develop their output torque. A DC SCR control must be able to supply the required voltage and current to operate the motor under all conditions of load and speed. Note: Do not assume that having the required horsepower is sufficient information to size the control. You will need to know the maximum voltage and current.
Section 1 General Information Final Installation After the control has been mounted and wired, the final settings can be made. 1. The CALC PRESETS, CMD OFFSET TRIM (if using any analog mode), and CUR LOOP COMP auto tune tests should be performed. Close the armature contactor when doing the CUR LOOP COMP test. 2. The elevator should be operated at inspection speed to set the FEEDBACK DIRECTION and verify the jumper settings on the DC tachometer expansion board (if one is installed).
Section 1 General Information Final Adjustments Roughness and instability of motor operation are often the result of a loosely mounted feedback device. Incorrect adjustment of the Level 1 DC Control, ARM PROP GAIN parameter and/or the SPEED PROP GAIN can also cause speed instability and oscillation of the car. Note: It is desirable to have the ARM PROP GAIN as high as possible without oscillation and the SPEED PROP GAIN as low as possible without rollback or overshoot.
Section 1 General Information Recommended Power Up/Down Sequence for Elevators Using DC SCR Controls The following is a recommended sequence for turning on and off the elevator drive and external OEM control. Figure 5-4 shows this sequence. Figure 5-4 Typical Power Up/Down Sequence for DC SCR Controls.
Section 1 General Information Inverter Controls AC induction motors may have their speed adjusted by using an AC Inverter (VVVF) to change the voltage and frequency supplied to the motor. The motor speed will be relatively proportional to the frequency supplied. An AC Inverter must be able to supply the amount of current the motor requires both on a continuous and peak basis under all conditions of load and speed.
Section 1 General Information Recommended Power Up/Down Sequence for Elevators Using Inverter Controls The following is a recommended sequence for turning on and off the elevator drive and external OEM controller. Figure 5-5 shows this sequence. 1. Close the M-Contactor. 2. Close the drive ENABLE. 3. Use the DRIVE ON opto output to energize an external coil for a relay to perform the following: 4. 5-6 Set-Up Information a.
Section 1 General Information Recommended Power Up/Down Sequence for Elevators Using Inverter Controls The following is a recommended sequence for turning on and off the elevator drive and external OEM control. Figure 5-5 shows this sequence. Figure 5-5 Power Up/Down Sequence for Inverter Controls.
Section 1 General Information Vector Controls Equipment Required New Installations Modernization If this is a modernization, do not disconnect the old control from the motor. It is needed to operate the motor for some preliminary measurements before it is disconnected. See Modernization. The following equipment is required for this upgrade. 1. Elevator rated AC induction motor with encoder installed. 2. Baldor Series 18H or 22H Vector Control. 3.
Section 1 General Information Modernization Continued 3. Apply power to the existing elevator control wiring and the Vector Control. 4. Refer to Table 5-2 “Pre-Installation Tests”. Perform all tests with the elevator connected in this temporary configuration. It is important to record all information for future use. These tests are performed with the existing elevator control. 5. Balanced Car Test a. A balanced elevator car is required for this test. b.
Section 1 General Information Final Wiring Connections 1. Disconnect all electrical power to all controls. 2. Disconnect the temporary wiring that was used for the Pre-Installation tests from the Vector control. 3. Connect the Vector control to the AC line, motor and encoder as shown in the Installation and Operating Manual supplied with the Vector control. Refer to the sections in that manual for recommendations on wire size, terminal torques, grounding, noise and other pertinent information. 4.
Section 1 General Information Initial Set-up If the Vector control has already been programmed by the OEM, the correct motor data has been installed. If this information has not been programmed, set the correct parameter values (refer to the interface specifications from the elevator controller OEM).
Section 1 General Information Initial Set-up Continued j. Set Level 1 VECTOR CONTROL Block, SLIP FREQUENCY as desired. This value can be calculated from the values recorded previously in Table 5-2. Record these calculated values in Table 5-3. Calculate the Slip RPM of the motor: Slip RPM + (RPM of Balanced Car) * (RPM of Fully Loaded Car) Calculate the % of Motor Loading: % Rated Motor Load + AC Motor CurrentǓ X 100% ǒFull Load Rated Motor Amps Determine the Slip Adjustment Value from Table 5-1.
Section 1 General Information Recommended Power Up/Down Sequence for Elevators Using Vector Controls The following is a recommended sequence for turning on and off the elevator drive and external OEM control. Figure 5-2 shows this sequence. 1. Close the M-Contactor. 2. After a 20mSec minimum delay (to ensure the M Contactor is closed), close the drive ENABLE input. This will allow current to flow and the IGBT’s to begin switching. 3.
Section 1 General Information Table 5-2 Pre-Installation Tests Date: Customer: Address: Elevator Location: Address: Motor Ratings (From Nameplate) Rated Voltage: Rated Current: Rated Speed (RPM): Rated Frequency: Installation Data Encoder Counts (PPR): Operating Mode: Dynamic Operating Conditions Balanced Car Test UP DOWN UP DOWN AC Line Voltage AC Motor Current Speed (RPM) Full Load Test AC Line Voltage AC Motor Current Speed (RPM) 5-14 Set-Up Information MN770
Section 1 General Information Table 5-3 Vector Control Worksheet Date: Catalog Number: Rated Voltage: Rated Horse Power: Rated Current: Slip RPM: % Rated Motor Load: Slip Adjustment Value: Slip Frequency: Installed by: Date: MN770 Set-Up Information 5-15
Section 1 General Information 5-16 Set-Up Information MN770
Section 6 Troubleshooting DC SCR Control Roughness of car ride quality and instability of motor operation are often a result of poor mounting of the feedback device. Incorrect adjustment of the ARM GAIN and/or the RATE PROP GAIN can also cause speed instability and oscillation of the car. If adjustment of RATE PROP GAIN does not help, check the feedback device for misalignment, slippage, sensitivity to mechanical vibration.
Section 1 General Information Electrical Noise Considerations All electronic devices including a Series H Control are vulnerable to significant electronic interference signals (commonly called “Electrical Noise”). At the lowest level, noise can cause intermittent operating errors or faults. From a circuit standpoint, 5 or 10 millivolts of noise may cause detrimental operation. For example, analog speed and torque inputs are often scaled at 5 to 10 VDC maximum with a typical resolution of one part in 1,000.
Section 1 General Information Electrical Noise Considerations Continued Combining an R-C snubber and twisted-pair shielded cable keeps the voltage in a circuit to less than 2 V for a fraction of a millisecond. The waveform shown in Figure 6-3 in addition to the snubber across the coil, the adjacent wire is grounded in a twisted–pair, shielded cable. Note that the vertical scale is 1 V/div., rather than the 20 V/div. in figures 6-1 and 6-2.
Section 1 General Information Electrical Noise Considerations Continued Wires between Controls and Motors Output leads from a typical 460 VAC drive controller contain rapid voltage rises created by power semiconductors switching 650V in less than a microsecond, 1,000 to 10,000 times a second. These noise signals can couple into sensitive drive circuits as shown in Figure 6-5. For this waveform, a transient induced in 1 ft. of wire adjacent to motor lead of a 10 hp, 460 VAC drive. Scope is set at 5 V/div.
Section 1 General Information Electrical Noise Considerations Continued Even input AC power lines contain noise and can induce noise in adjacent wires. This is especially severe with SCR controlled DC drives, current–source and six–step inverters. Figure 6-9 shows a transient induced in 1–ft. wire adjacent to AC input power wire to 20 hp, DC drive. Scope is set at 500 mV/div. and 2 sec/div.
Section 1 General Information Electrical Noise Considerations Control Enclosures Continued Motor controls mounted in a grounded enclosure should also be connected to earth ground with a separate conductor to ensure best ground connection. Often grounding the control to the grounded metallic enclosure is not sufficient. Usually painted surfaces and seals prevent solid metallic contact between the control and the panel enclosure.
Section 1 General Information Wiring Practices The type of wire used and how it is installed for specific applications makes the difference between obtaining reliable operation and creating additional problems. Power Wiring Conductors carrying power to anything (motor, heater, brake coil, or lighting units, for example) should be contained in conductive conduit that is grounded at both ends. These power wires must be routed in conduit separately from signal and control wiring.
Section 1 General Information Optical Isolation Isolating electrical circuits with some form of light transmission reduces the electrical noise that is transmitted from one part of a circuit to another. That is, an electrical signal is converted to a light signal that is transmitted to a light receiver. This converts the light back to an electrical signal that has less noise than the input. Two methods are commonly used; optical couplers and fiber optics.
Appendix A Load Weighing / Torque Feed Forward In many advanced elevator applications, the system is designed to weigh the elevator load to offset the counterweight of the car. We also refer to this as a torque feed forward application. Both the Baldor AC Vector (Series 18H and 22H) and Series 20H SCR Controls can be programmed to use the torque feed forward option (Level 1 Input block; Command Select parameter, 10V w/Torq FF). In a typical installation, a car is balanced with a 40% load.
Section 1 General Information The parameters and inputs used for torque feed forward are indicated in the Table A-1. For a Vector control, the OPERATING MODE selected will be BIPOLAR or 15 SPEED. For a Series 20H DC SCR control, BIPOLAR HOIST or 7 SPEED HOIST should be selected.
Appendix B Serial Communications Baldor’s Series 15H and 21H Inverters, 20H DC SCR or 18H and 22H Vector controls may be monitored or operated remotely by a modem an a Serial Communication expansion board on the control. By using either the EXB001A01 or EXB002A01 Serial Communications boards for RS-232 communications, the control parameters and diagnostic menus may be viewed and parameter values changed from a remote computer.
Section 1 General Information B-2 Appendix B MN770
Appendix C Elevator Industry Glossary Adjusters – The elevator mechanic who does advanced maintenance or supervisory functions in conjunction with mechanics. Approach Speed – A fixed speed sometimes used on high speed elevators as an intermediate speed for the last few feet before switching to the leveling speed. Balanced Car – A condition where the elevator car is balanced by adding weights into the car equal to the counterweight.
Section 1 General Information Gearless Elevator – An elevator powered by a low speed motor (usually DC) which has the drive sheave mounted directly on the motor shaft. It uses no gearbox. These are used in high speed elevators. Typical motor speeds are 70 -150 RPM at contract speed. Governor – A mechanical speed measuring device propelled by a cable suspended from the elevator. As speed increases, centrifugal force causes counterweights to move and signal the controller of a fault condition.
Section 1 General Information Pattern Generator – An external circuit board used to generate an adjustable S–curve speed command for smooth acceleration and deceleration. This signal is used by the motor control instead of any on–board S–curve. It uses feedback from the elevator by means of a DC tach or encoder. Pit – The area below the elevator at the bottom of the hoist way. It usually contains a buffer or other means of stopping the car during emergencies.
Section 1 General Information C-4 Appendix C MN770
BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft.
